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Feasibility Report Madian Hydropower Project

7166P02/Vol. II, BoQ and Cost Estimates

9Bill of Quantities and

Cost Estimates



Table of Contents 9. Bill of Quantities and Cost Estimates 9-1

9.1 General 9-1

9.2 Methodology Applied to Estimation of Project Costs 9-2

9.3 Basis of Cost Estimation 9-3

9.4 Estimation of Direct Project Costs 9-3

9.4.1 Estimation of Civil Costs 9-4

9.4.2 Estimation of Costs of Hydraulic Steel Structure Equipment 9-9

9.4.3 Estimation of Costs of Electro-mechanical Equipment 9-10

9.4.4 Estimation of Costs of Electrical Equipment 9-11

9.5 Estimation of Indirect Project Costs and Contingencies 9-12

9.5.1 Consideration of Indirect Costs and Contingencies 9-12

9.5.2 Consideration of Import Charges 9-14

9.6 Estimation of Costs for Project Development 9-14

9.6.1 Estimate for Cost of Engineering and Administration 9-14

9.6.2 Estimate for Cost of Client’s Own Costs 9-14

9.7 Bill of Quantities 9-15

9.8 Total Construction Cost and Basic Project Cost 9-15

9.9 Disbursement of Costs – Cash Flow 9-16

9.10 Operation, Maintenance and Repair Costs 9-18



List of Annexes:

Annex A-9.1: Quotation of Material Unit Prices of Manufacturers /Suppliers

Annex A-9.2: Cost of Construction Equipment - Monthly Rental

Annex A-9.3: Comparative Statement of Unit Rates of 6 Hydropower Projects

Annex A-9.4: Bill of Quantities of Madian Hydropower Project

Annex A-9.5: Cost Estimate of Hydraulic Steel Structure Equipment

Annex A-9.6: Cost Estimate of Electro-mechanical Equipment

Annex A-9.7: Cost Estimate of Electrical Equipment


7166P02/BoQ and Cost Estimates 9-1

9. Bill of Quantities and Cost Estimates

9.1 General

This report summarizes selected key parameters for the estimation of costs of the Madian Hydropower Project and the cost estimate itself for all its major components. During the pre-feasibility stage the Consultant setup a preliminary unit cost data base and carried out the cost estimates for assessment of the alternative project layouts. At the beginning of the feasibility study the Consultant updated all relevant economic key parameter in co-ordination with the Project Sponsor and elaborated a detailed Project unit cost data base. At the time of submission of the draft feasibility report the Consultant escalated the respective unit rates and costs to the level at the end of the fiscal year 2007-2008. Basic costs of labour, material, consumables and equipment were inquired, unit costs calculated and compared with unit rates of hydropower projects of similar size and type presently under development in Pakistan. These unit rates were used for the optimization of the installed capacity and the dimensions of the major project structures. Based on the feasibility design as documented by the corresponding design drawings the Consultant determined the quantities of the major civil project structures and equipment components. For minor works provisions in terms of the item miscellaneous are made. In accordance with common practice the cost estimate is based on the concept of direct and indirect costs and provisions for unforeseen items and costs (contingencies). The cost estimate includes the following main plant components and cost elements: • land acquisition

(according to Resettlement Action Plan, Feasibility Study, Vol. VI-b); • land clearing and access; • mobilisation cost and site infrastructure; • surveys and investigations (e.g. hydraulic model tests); • civil works: weir with spillway & flushing outlet, power intake,

headrace tunnel, surge tank, pressure shaft and tunnel, powerhouse, and tailrace system;

• material disposal sites; • manufacturing, transport erection, installation, testing and

commissioning of: - hydraulic steel structures, - electro-mechanical and electrical equipment,

• environmental and social impact mitigation costs; • taxes and import duties; • administration and legal costs; • engineering and supervision costs; • finance and insurance; • Sponsor’s costs prior to commercial operation; etc.



9.2 Methodology Applied to Estimation of Project Costs

The methodology applied to the estimation of cost for the Madian Hydropower Project is carried out proceeding the following steps in accordance with the requirements of a bankable feasibility study. 1. Define Basis of Cost Estimation 2. Estimate Basic Project Costs expressed in terms of Direct Costs: 2.1 Estimate Direct Costs for Civil Works; 2.2 Estimate Direct Costs for Electro-mechanical Equipment 2.3 Estimate Direct Costs for Electrical Equipment 2.4 Estimate Direct Costs for Steel Structure Equipment 3. Estimate Contingencies and Indirect Costs 3.1. Estimate Costs for Land Acquisition 4. Cost of Project Development 4.1 Estimate Costs of Engineering and Administration 4.2 Estimate Owners Own Costs 5. Determine Bill of Quantities 6. Estimate Total Project Costs 7. Estimate Operation and Maintenance Costs In addition to the basic cost items of each civil structure in terms of their direct costs, the Consultant considered certain contingencies. These contingencies play an important role for the project viability, they include both physical and price contingencies. Physical contingencies result from the fact that the estimated quantity of certain items might have been underestimated. Additional minor items or quantities and components will ultimately be required which were based on the knowledge available at the particular planning level originally not included in the estimate. Certain adjustments are commonly required with advancing level of planning and during the implementation phase, etc. Price contingencies are included to account for variation in prices, i.e. inflationary tendencies, during the implementation period. Physical contingencies will be estimated as a percentage of the base price of equipment and engineering services, whereas price contingencies will be determined on the basis of the forecast rate of inflation for both the local and foreign currency portions. The following sections describe the methodology of the approach to cost estimation described above for each activity in the required detail. We will split the cost estimate into local and foreign currencies. Moreover, a disbursement plan will be included that provides the necessary information on when particular investment payments are due.



9.3 Basis of Cost Estimation

The following assumptions were made by the Consultant based on his experience in coordination with the Project Sponsor as the basis for the present Feasibility Study:

June 30th 2008 1 US$ = 67.98 Rps. (PAK)

Table 9.1: Basic Exchange Rate for Local to Foreign Currency

All costs will be expressed in the foreign currency US$. Local market prices and rates will be converted to foreign currency applying the exchange rate of the Central Bank of Pakistan at the selected reference dates. In co-ordination with the Project Sponsor the reference date applied to the present feasibility study is June 30th 2008, which corresponds to the end of the fiscal year 2008. Costs are presented by their local and foreign cost component for the individual unit rates and the overall cost of civil works and equipment. The composition of the local and foreign cost component was derived from hydropower projects presently under development in Pakistan.

9.4 Estimation of Direct Project Costs

The direct costs of a hydropower project are commonly estimated separated for the following major components based on the major items/elements.

a) Civil works; b) Hydraulic steel structure equipment; c) Electro-mechanical and d) Electrical equipment;

The civil costs comprise more than 70 % of total project costs in the particular case of the Madian HPP. Therefore, determination of the corresponding unit rates is discussed in detail in the following chapter in the required detail. Cost of permanent equipment is based on tender costs of hydropower and thermal power (electrical equipment only) projects of similar type and magnitude. In view of the tight market situation the willingness of manufacturers / suppliers to provide quotations for the equipment specified for the Madian HPP has fallen to a low level since most of the established manufacturers state having orders for more than one year of their production capacity.



9.4.1 Estimation of Civil Costs

The cost estimates forms the basis of the economical and financial evaluation of the project. It shall be prepared on the basis of representative unit rates for the various construction activities and the respective quantities. In order to comply with the requirements on accuracy of the cost estimates as established in the Terms of Reference, the Consultant followed the following approach:

1. Collect basic costs of materials, fuel, energy, consumables, labour, equipment etc ex factory and at site (cost of transport).

2. Calculate unit rates for relevant items of civil works for application to the BoQ;

3. Collect unit rates used in feasibility studies and tendering of Hydropower Projects of similar type and magnitude; escalate these unit to the reference data of the cost estimate;

4. Compare, analyse and conclude on most appropriate unit rates for application.

9.4.1.1 Cost of Major Material Items

The Consultant contacted potential manufacturers and suppliers of the major material items required for construction of the Madian HPP such as cement, reinforcement steel, diesel fuel, explosives, gabion mesh, geotextile etc. The Suppliers were requested to provide a unit rate ex-factory/store and at site to account adequately for transport cost.

Cost of Material

Material Item Manufacturer Unit Ex Factory Freight At Site

Supplier Rps. Rps Rps US$ Cement Askari Cement Rs / ton 4,350.0 600.0 4,950.0 77.2 Cherat Cement Rs / ton 4,500.0 574.0 5,074.0 79.2 Reinforcement Steel Fazal Steel Rs / ton 63,600.0 2,190.0 65,790.0 1026.4 Amreli Steels Rs / ton 55,500.0 5,000.0 60,500.0 943.9 Explosives WAH NOBEL Rs / ton 191,980.0 2,812.0 194,792.0 3039.0Anfo WAH NOBEL Rs / ton 166,440.0 2,812.0 169,252.0 2640.6

Detonator WAH NOBEL Rs / 100 units 6,325.0 28.1 6,353.1 99.1

Detonatiung Cord WAH NOBEL Rs/1000m 16,820.0 2,812.0 19,632.0 306.3 Geomembran USA Lining Rs / m² 125.6 17.5 143.1 2.2 Gabion mesh Rs / m² 106.2 126.0 232.2 3.6

1 US$ = Rs. 64.31 January 2008

Table 9.2: Material Unit Rates Inquired from Suppliers and Manufacturers



Since the Project Sponsor is a cement manufacturer, cost of at least one alternative supplier has been inquired from the list of potential suppliers. Information such as distance of each factory from project site, capacity of production and type of cement produced has been taken into account in the assessment. The cement factory at Nowshehra is, e.g. within a distance of 275 km from Madian town.

The corresponding quotations for the respective construction materials are given in Annex A-9.1 and are summarized in Table 9.2. For the items listed in Table 9.2 rates were provided in local currency (Rupees) and converted in unit prices in USD.

The Consultant further inquired the cost of bore piling with D = 0.8 m diameter bore piles with two Contractors, a foreign contractor and a Pakistani contractor resulting in the following unit rates : KELLER, Germany 250 Euro/m² (single piles) 350 Euro/m² (overlapping piles) 308 US$/m (incl. concrete and reinforcem.) 352 US$/m (including mobilization.) DEEPWELL, Pakistan 15,000 Rps/m (drilling only) 233 US$/m (drilling only) 330 US$/m (incl. concrete and reinforcem.) For the present cost estimate a unit rate of US$/m 352 is applied. Drill bits, rods and other drilling consumables will have to be imported which will include custom duties & Govt. Taxes. Cost of these items is shown as under the respective unit rates.

9.4.1.2 Cost of Transportation of Construction Material

Provision for transport of heavy permanent equipments such as turbines generators, transformers & spillway gates, valves, steel liner etc is considered in the cost estimate of the hydraulic steel structure and electro-mechanical and electrical equipment.

Cost of transport of construction equipment if any is considered as part of mobilization (indirect costs). Cost of transport to project site need to be considered for the transport of construction material and consumables. The corresponding cost is estimated based on the distances and specific transport costs as follows:

By Railway & Road: From Karachi to Dargai be train and from Dargai to Project site by road

By Road: From Karachi to Project site road

Total Distance approximately 1,800 km.



Item Description By Road By Road

Reinforcement 5.32 Rps/ton km 0.08 US$/ton km

Cement 7.60 Rps /m³ km 0.11 US$/m³ km

Table 9.3: Unit Rates for Transport of Material to Project Site

9.4.1.3 Cost of Labour

The financial cost of labour rate was obtained from basic salaries used for different categories of labours on projects near Swat in NWFP as shown in National Statistical Bulletin issued by the Federal Government of Pakistan. The corresponding rates are shown in table 9.4. At the time of preparation of this feasibility report the figures for the reference date 30. June 2008 were not yet published and, therefore, adequately escalated.

Basic Premium Basic Total Total Foreign

Wage % Wage D/Shift 1.35

N/Shift 1.55

D/Shift N/Shift Description

Rps/ hr Rps/ hr Rps/ hr

Rps/hr Rps/hr US$/hr US$/hr

F-1 Foremen 1st Class

122.5 12.25 134.75

182 209 2.99 3.44

EOI Equipment Operator

62.5 6.25 68.75 93 107 1.53 1.75

HIS Highly skilled

40.6 4.06 44.66 60.29 69.22 1.00 1.15

SI Skilled Worker

35.0 3.50 38.50 52 60 0.87 1.00

SSI Semi Skilled 29.32 2.93 32.25 44 50 0.73 0.83

US Unskilled Labour

21.88 2.19 24.07 32 37 0.53 0.62

1 US$ = Rs. 60.63 June 2007

Table 9.4: Cost of Local Labour in Pakistan (as per 30. June 2007) The above given labour costs reflect data on local labour only. The Consultant assumes that in particular foreman, machine operators and skilled workers will be experienced staff of the appointed foreign contractor and thus higher hourly rates apply. The corresponding adjustments are made to the cost of labour to account for a mix of foreign and local labour with largely foreign staff for the highly qualified work and predominantly local staff for the semi and unskilled working activities.



9.4.1.4 Calculation of Unit Rates

Based on the collected cost of labour, materials, consumables and the adjustment of the Consultant’s list of equipment, calculation of unit rates for the major construction items was performed. The Consultant used its unit cost data base program and calculated unit rates based on the above mentioned components (labour, material, consumables, equipment) and applying the respective combination of these components required for execution of a unit of all relevant civil work activities in a similar way as a Contractor does in his calculation. Annex A-9.4 contains the relevant unit rates for the civil cost items of each major project structure together with the corresponding quantities. These rates where then checked with rates arrived at by using hourly rates of labour, equipment, material and fuel cost for common items constituting major part of the structure line excavation, concrete and dewatering, adjusted to site condition and other factors.

The above mentioned cost estimate is based on in-house databases, which have been developed from Fichtner’s experience in this field. Also, negotiated prices available from our activities on other projects will be used as reference. The construction costs will be determined on the basis of a quantity survey and adopting unit costs calculated by using material and labour costs valid for the project region. About 70 % of the total construction costs will be computed using a contractor's approach to calculate prices. The remaining 30% of the costs will be estimated based on experience.

9.4.1.5 Unit Rates of Similar Hydropower Projects

There is a large number of hydropower projects under development in Pakistan. The cost estimates and unit rates derived from the tender documents and the Contractor’s proposals of other hydropower projects of similar type and magnitude provide a reasonable orientation for the plausibility of the calculated unit rates. Site, contract and other specific conditions may, however, cause significant deviations in the unit rates for the same construction activity from one hydropower project to the other. The Consultant collected and analysed unit rates of civil works of the following hydropower projects to a reasonable extent similar in type and size to the Madian HPP:

1.) Malakand-III, 2.) Patrind HPP 3.) Golen Gol HPP 4.) Diamer Basha Dam Project 5.) Dubeer Khawar HPP 6.) Khan Khwar HPP



Since the units rates presented in the BoQ of the six above projects refer to different reference dates, they were escalated to the level of June 30, 2008 applying an appropriate inflation rate per annum on local and foreign currency rates and the corresponding currency exchange rate of the Central Bank of Pakistan. The comparison of the individual unit rates of the six hydropower projects for the major activities of civil construction are given in Annex A-9.3. Following the comparison and analysis of the unit rates of other projects, the unit rates given in Table 9.5 are recommended for application:

No Cost Item Unit Unit Rate

US $

1 Open Excavation in overburden m³ 7.602 Open Excavation in rock m³ 15.753 Open Excavation in rock m³ 16.80

for pits and trenches4a Underground rock excavation, Rock Type A m³ 141.75

incl. Disposal of muck4b Underground rock excavation, Rock Type B m³ 136.50

incl. Disposal of muck4c Underground rock excavation, Rock Type C m³ 126.00

incl. Disposal of muck5 Backfill with excavation material m³ 5.806 Shotcrete m³ 172.007 Reinforcement to 1240.008 Concrete lining incl. Formwork m³ 174.009 Reinforced Concrete incl. Formwork m³ 170.00

Table 9.5: Unit Rates for Civil Works from Other Hydropower Projects



MADIAN HYDROPOWER PROJECT COST IN (USx1000) COST IN Million US $

LOCAL FOREIGN TOTAL

DIVERSION WORKS 4.201,2 4.588,5 8,790U/S coffer Dam 920,2 746,2 1,666D/s Coffer Dam 239,2 185,6 0,425Diversion Tunnel 3.041,8 3.656,7 6,699

CONCRETE WEIR 5.895,3 7.088,0 12,983Main Weir Body 4.530,6 3.990,4 8,521Foundation Treatment (Borepiling) 722,9 2.313,2 3,036Grouting 641,8 784,4 1,426

RESERVOIR PROTECTION WORKS 1.771,9 869,2 2,641HEADRACE 47.015,0 66.565,4 113,580Intake 933,2 912,1 1,845Tunnel 45.495,8 64.814,5 110,310Construction adits 586,0 838,8 1,425

Desander Cavern 9.974,6 14.730,5 24,705Caverns 9.632,6 14.211,2 23,844Construction adits 341,9 519,3 0,861

PRESSURE SHAFT / TUNNEL 823,5 1.152,7 1,976Pressure Shaft 339,4 486,3 0,826Pressure Tunnel 155,4 227,0 0,382Manifolds 328,7 439,4 0,768

TAILRACE TUNNEL 1.582,8 1.838,2 3,421Draft tube Extension & Tailrace Tunnel 1.006,6 1.310,7 2,317Tailrace tunnel & Power Outlet 576,2 527,5 1,104

SURGE TANK 2.482,1 3.487,9 5,970POWERHOUSE CAVERN, TRANSFORMER & SWITCHYARD GALLERY 4.762,8 5.817,1 10,580Powerhouse Cavern 3.206,1 3.709,6 6.915,7Transformer & Switchyard Cavern 603,8 732,3 1.336,1Cable Tunnel 203,8 286,2 490,0Access Tunnel 749,1 1.089,1 1.838,2

ACCESS ROADS & BRIDGES 489 224 0,713TOTAL 78.997,8 106.361,4 185.359,2

9.4.1.6 Civil Cost of Madian Hydropower Project

Based on the unit rates established in the Consultants unit cost data base and the detailed Bill of Quantity of the Project (see Annex A-9.4), the cost of the civil works was estimated as given in Table 9.6 Table 9.6: Costs of Civil Works of Madian Hydropower Project

9.4.2 Estimation of Costs of Hydraulic Steel Structure Equipment

The cost estimate of the hydraulic steel structure equipment for the Madian HPP is based on tender costs of hydropower projects of similar type and magnitude worldwide. In view of the tight market situation the willingness of manufacturers / supplies to provide quotations for the equipment specified for the Madian HPP is low. Equipment costs were estimated based on the cost of material that international manufacturers pay for purchase of material and the corresponding charges for design and manufacturing, transport, insurance and erection etc. as known from tender prices of similar type of equipment.



UNIT RATENo. DESCRIPTION UNIT QUANTITY Local Foreign Total

US$ US$ US$1 Turbines Lumpsum 1 1.872.687 13.108.807 14.981.4932 Butterfly valve, D=2.5m Lumpsum 1 382.592 2.678.143 3.060.7353 Cooling Water System Lumpsum 1 166.461 1.165.227 1.331.6884 Drainage and Dewatering System Lumpsum 1 69.359 485.511 554.870

5a Low Pressure Compressed Air System Lumpsum 1 26.356 184.494 210.8515b Low Pressure Compressed Air System Lumpsum 1 33.781 236.469 270.2516 Air Conditionning and Ventilation System Lumpsum 1 188.779 1.321.452 1.510.2317 Oil Treatment Plant Lumpsum 1 16.579 116.053 132.6328 Mechanical Workshop Equipment Lumpsum 1 31.905 223.335 255.2409 EOT Crane Powerhouse 210 t Lumpsum 1 118.134 826.935 945.0699 Elevator Lumpsum 1 33.281 232.967 266.248

10 Fire Fighting System Lumpsum 1 99.575 697.022 796.59711 Auxiliary Francis unit - 520kW Lumpsum 1 150.799 1.055.592 1.206.390

Subtotal 3.190.287 22.332.008 25.522.295-Miscellaneous items % 2,5 638.057TOTAL in US$ 26.160.353

UNIT RATENo. DESCRIPTION Local Foreign Total

US$ US$ US$1 Diversion Tunnel Intake Stoplogs 302.400 100.800 403.2002 Spillway Gates and Stopglogs 452.484 3.167.391 3.619.8753 Flushing Outlet - Steel Liner and Gates 317.835 476.753 794.5884 Power Intake, Gates, Stoplogs, Raking Machine 466.298 1.398.895 1.865.1945 Desander gates 1.027.688 1.027.688 2.055.3756 Headrace Tunnel Maintenance Gate 36.094 252.656 288.7507 Pressure Shaft/Tunnel Steel Liner 1.884.157 332.498 2.216.6558 Powerhouse 55.420 387.942 443.3639 Tailrace Outlet 192.938 64.313 257.250

SUBTOTAL 4.735.314 7.208.935 11.944.249

In Table 9.7 the major components of the hydraulic steel structure equipment and their corresponding costs are given. A detailed list of equipment part and their corresponding rates and quantities is given in Annex A-9.5. The level of the prices is 30. June 2007. Table 9.7: Cost of Hydraulic Steel Structure Equipment for the Madian HPP The Consultant inquired/estimated actual rates as per 30. June 2008. An increase of costs of approximately 15 % within one year was observed. In view of establishing additional steel production capacities in China and India, predictions are reported that in the near future escalation of costs will be moderate or even stagnant.

9.4.3 Estimation of Costs of Electro-mechanical Equipment

The cost estimate of the electro-mechanical equipment is based on tender costs of hydropower projects of similar type and magnitude worldwide. In view of the tight market situation the willingness of manufacturers / supplies to provide quotations for the equipment specified for the Madian HPP is low. Leading manufacturers state having orders for more than one year of their production capacity. The equipment costs were estimated based on recent tender prices of projects of similar type of equipment from qualified manufacturers on the basis of equipment lists broken down into CIF prices, transportation to site, erection and commissioning. Table 9.8: Cost of Electro-mechanical Equipment for the Madian HPP



UNIT RATENo. DESCRIPTION UNIT QUANTITY Local Foreign Total

US$ US$ US$1 Synchronous generators 63 kVA, 333 r Lumpsum 1 2.525.473 17.678.311 20.203.7842 Step-up transformer 230/13.8 kV Lumpsum 1 882.853 6.179.969 7.062.8223 220 kV SF6 Switchyard Lumpsum 1 742.180 5.195.259 5.937.4384 220 kV Terminal Gantry & Auxil. Lumpsum 1 76.431 535.017 611.4485 13.8 kV generator busbars & auxil. Lumpsum 1 353.368 2.473.575 2.826.9436 Protection Systems Lumpsum 1 261.487 1.830.407 2.091.8947 Control and Monitoring System Lumpsum 1 332.464 2.327.247 2.659.7118 Electrical Equipment at Dam Site Lumpsum 1 171.090 1.197.629 1.368.7189 El. Equipment at Desander Cavern Lumpsum 1 92.523 647.664 740.188

10 Emergency Diesel 630 kVA Lumpsum 1 54.576 382.031 436.607Subtotal 43.939.553-Miscellaneous items % 0 0

in US$ 43.939.553

In Table 9.8 the major components of the electro-mechanical equipment and their corresponding costs are summarized. A detailed list of equipment parts and their corresponding rates and quantities is given in Annex A-9.6. The Consultant inquired/estimated actual rates as per 30. June 2008 (one year later) and observed an increase of costs of approximately 20 %. It is difficult to make predictions on future development of equipment prices. The Consultant believes that in the near future escalation of costs will be moderate.

9.4.4 Estimation of Costs of Electrical Equipment

The cost estimate of the electrical equipment is based on the tender costs of hydropower and thermal power projects worldwide. In view of the tight market situation the willingness of manufacturers / supplies to provide quotations for the equipment specified for the Madian HPP is low. Leading manufacturers state having received orders for far more than one year of their production capacity. The equipment costs were estimated based on recent tender prices of projects with similar type of equipment on the basis of equipment lists from qualified manufacturers and broken down into CIF prices, transportation to site, erection and commissioning. In Table 9.9 the major components of the electrical equipment and their corresponding costs are summarized. A detailed list of equipment parts and their corresponding rates and quantities is given in Annex A-9.7. Table 9.9: Cost of Electrical Equipment for the Madian HPP The Consultant inquired/estimated actual rates as per 30. June 2008. An increase of costs of approximately 25 % within one year was observed. It is difficult to make predictions on the future development of equipment prices. The Consultant believes that in the near future escalation of costs will be moderate.



9.5 Estimation of Indirect Project Costs and Contingencies

9.5.1 Consideration of Indirect Costs and Contingencies

The cost estimate for a hydropower project comprises major construction activities and cost items with their corresponding unit rates and quantities or where applicable lump sum cost. The total construction cost is determined as the sum of the direct and indirect costs plus contingencies. The basic project cost is calculated as the total construction cost plus charges for engineering, administration and supervision as well as client's own costs, the latter two expressed as a percentage of the total construction costs. Indirect costs, as outlined below in detail, are costs other than investment and recurrent costs and concern activities which will be required as a result of the construction of the project infrastructure. They will depend on the final project development plan recommended for implementation, and will be determined on the basis of the results provided by the social studies, institutional support requirements and the Environmental Impact Assessment, including necessary compensation or mitigation measures to alleviate negative impacts, where applicable.

9.5.1.1 Consideration of Indirect Costs

As common practice in bankable feasibility studies, the concept of indirect costs is applied to civil costs and includes preparation of the construction sites, camp installation, site administration as well as bonds, insurance and contractor’s profits. Indirect costs are taken to 25 % of the direct cost, estimated as follows:

- 10% for site installation cost not included in the direct cost such as: − move in, move out, erection, operation, maintenance and repair of general

equipment, machinery, work-yards, stores, offices and housing facilities − move in and move out and all other relevant cost of personnel − general services such as electric power, water, sewage, traffic,

communication, − camps, canteen, special installations, first-aid, fire fighting, etc. − temporarily required roads and bridges

- 15% for the contractors indirect cost consisting of: − site overheads for key personnel and local staff expenses 2.0% − head office services 2.0% − bonds and insurance 2.0% − pre-financing cost 5.0% − miscellaneous general services 1.0% − risk and profit 3.0%

In addition costs related to land acquisition, compensation payments and resettlement are to be taken into account.



Relevant corresponding costs may include:

• Land acquisition costs and compensation payments for loss of agricultural production; these were determined as part of the Resettlement Action Plan (RAP, see Volume VI-b);

• Resettlement costs for households to be resettled due to the construction project components, dumping of excavation material, these were determined as part of the Resettlement Action Plan (see Volume VI-b);

The costs related to land acquisition, compensation payments and resettlement were determined to amount to RAP Cost: 129.395 million Rupees equivalent to 2.134 million USD In addition the Consultant considers some minor additional annual costs for monitoring of water quality and supply of drinking water to affected households as outlined in detail in Volume VI-b of this Feasibility Study. The corresponding costs are included in the estimate of Operation and Maintenance Costs.

9.5.1.2 Consideration of Contingencies

Irrespective of the level of planning, some element of uncertainty will still remain in the estimation of quantities and costs, for which usually physical contingencies are included in the cost estimates to cover, for example, the following: - unforeseen construction items, - errors or inaccuracies in the quantity calculations, - unforeseen deviations from expected geological, topographical or

hydrological values. The percentage additions to the direct cost to account for physical contingencies are defined in the Bill of Quantities. For the feasibility study of the Madian HPP the following values were taken (Contingencies cover both the physical and financial components). For the level of a bankable feasibility study the following provisions are made to account for unforeseen works and costs:

a) Civil works 10.0 % b) Electromechanical Equipment 7.5 % c) Electrical Equipment 7.5 % d) hydraulic Steel Structure Equipment 7.5 %



9.5.2 Consideration of Import Charges

The Consultant inquired the extent of import charges which would apply for import of electro-mechanical, electrical and particular hydraulic steel structure equipment to be adequately considered in the estimation of costs. For equipment such as turbines generators and other special equipment not fabricated in Pakistan an import charge of 5.0 % applies. In the estimation of costs excise fees at Karachi harbour are to be taken into account in addition. According to the Consultant’s information a national excise fee of 1.0 % will be charged for imported equipment and in addition an excise fee will be charged by the state of Sindh of 0.5 %. For clearance and handling some minor fees will be charged within the harbour area which are estimated as a total amount of 0.5 %. In total 7.0 % of import charges are therefore applied to the above mentioned imported equipment and considered in the Bill of Quantities and the estimation of costs to account for import and related charges.

9.6 Estimation of Costs for Project Development

9.6.1 Estimate for Cost of Engineering and Administration

The cost of all required activities for Engineering and Administration, setting up the legal and institutional framework of the Project after completion and acceptance of the feasibility study is estimated applying a certain percentage of the total cost of the project cost. Assuming that tender design, assistance in the tender process and supervision of construction, erection and commissioning will be conducted by a leading international consultant, an estimate of 6 % of civil works and 3 % for hydraulic steel structure, electro-mechanical and electrical equipment cost is made. The assumed rate accounts for the present situation in the market and the particular the conditions of the political instability in Pakistan and the corresponding required provisions for security aspects etc..

9.6.2 Estimate for Cost of Client’s Own Costs

The cost of all related expenditures of the Client in the course of developing the Project after completion and acceptance of the feasibility study is estimated applying a percentage of the total cost of the project. As a common approach an estimate of 1.0 % of the total project cost is made for this bankable feasibility study taking into account the requirements of legal support for negotiation of the Power Purchase Agreement (PPA) and other related activities in the volatile North Western Frontier Province of Pakistan.



9.7 Bill of Quantities

Civil works costs are determined by multiplying the computed quantities of work with the respective compound rates. For civil works (and for selected equipment) element-specific 'miscellaneous costs' are added to cover expenditures for minor items, which have not separately been considered, expressed as a percentage of the total cost of the respective element. The Consultant determined the quantities of works for each major civil structure based on the feasibility design drawings applied an adequate number of profiles to reflect adequately both the dimensions of the structure, the topographic (as regards excavation) and the geological conditions. At the headrace tunnel as the major cost item of the project, in the estimation of the quantity of rock excavation provisions are made in addition to excavation of the net tunnel diameter for concrete lining, shotcrete and a certain overbreak. The thickness of lining and shotcrete as well as the length and density of rock bolts vary with the rock classes to be encountered along the tunnel alignment. This variation has been taken into account applying the geological assessment of the headrace tunnel and the allocation of rock classes to the individual tunnel sections. For each tunnel section the corresponding rock support (see report on Geology, Section 3.4) is considered in the estimation of quantities. Table 9.6 summarizes the major quantities of civil works of the Madian HPP

9.8 Total Construction Cost and Basic Project Cost

As discussed in the previous sections the total project cost are calculated applying provisions for indirect costs, contingencies, import charges, engineering and administration and client’s own costs as summarized in Table 9.10.

Cost item (%) Indirect civil costs (% of direct civil costs) 25 Contingencies (% of direct + indirect costs) - civil 10.0 - electro-mechanical 7.5 - electrical 7.5 Engineering and administration 6.0 / 3.0 Client’s own costs 1.0

Table 9.10 : Indirect Costs and Contingencies The corresponding composition of the total costs of the Madian HPP is given in Table 9.12.



9.9 Disbursement of Costs – Cash Flow

Based on his experience the Consultant elaborated a Project cash flow for the construction period to achieve an adequate disbursement of costs and the corresponding estimation of interest during construction. As a conservative estimate an advance payment of 20 % is assumed for the civil contractor. Further payments are nearly constant since major part of construction activities are underground works with rather constant production rates which are not affected by climatic conditions. A certain variation of the progress of work and the corresponding cash flow is considered with a slightly higher percentage for the summer period compared to the winter period when concrete work, drilling etc. may be affected by climatic conditions. A slightly distinctive approach is made for the manufacturer/supplier of electro-mechanical and steel structure equipment on one hand and that of the electrical equipment on the other. The Consultant observed that the market situation is intense as regards vacant capacities of manufacturers of transformer and generators. The cost estimate and the percentage of the advance payment were adjusted to account for this situation as shown in the cash flow schedule indicated in Table 9.11.

year 1 year 2 year 3 year 4 year 5Contractor / Month 0 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 TotalCivil Contractor 20 3 3 4 4 4 5 5 3 3 5 5 3 3 5 5 5 5 10 100E&M Equipment 10 20 15 15 15 15 10 100Electrical Equipment 20 15 15 20 20 10 100Steel Struct. Equipm. 10 20 15 15 15 15 10 100

Table 9.11: Disbursement of Cost during Construction for EPC Contractors



COST CATEGORY Charges Local Foreign Total % of Total1000 US$ 1000 US$ 1000 US$

CIVIL COSTS 78.998 106.361 185.359 50,6% CONTINGENCIES 10,00% 7.900 10.636 18.536 5,1% INDIRECT COST 25,00% 21.724 29.249 50.974 13,9% ENGINEERING / ADMINISTRATION 6,00% 6.517 8.775 15.292 4,2%

SUBTOTAL CIVIL COSTS 115.139 155.022 270.161 73,8%STEEL STRUCUTRE EQUIPMENT 4.735 7.209 11.944 3,3% CONTINGENCIES 7,50% 355 541 896 0,2% IMPORT CHARGES & FEES 7,00% 542 0 542 0,1% ENGINEERING 3,00% 153 232 385 0,1%

SUBTOTAL STEEL STRUCTURE EQUIPMENT 5.786 7.982 13.768 3,8%ELETRO-MECHANICAL EQUIPMENT 3.270 22.890 26.160 7,1% CONTINGENCIES 7,50% 245 1.717 1.962 0,5% IMPORT CHARGES & FEES 7,00% 1.722 0 1.722 0,5% ENGINEERING 3,00% 105 738 844 0,2%

SUBTOTAL ELECTRO-MECH. EQUIPMENT 5.343 25.345 30.689 8,4%ELECTRICAL EQUIPMENTS 5.492 38.447 43.940 12,0% CONTINGENCIES 7,50% 412 2.884 3.295 0,9% IMPORT CHARGES & FEES 7,00% 2.893 0 2.893 0,8% ENGINEERING 3,00% 177 1.240 1.417 0,4%

SUBTOTAL ELECTRICAL EQUIPMENT 8.975 42.571 51.545 14,1%SUBTOTAL w/o ENGINEERING 128.290 219.934 348.224 95,1%SUBTOTAL 135.243 230.920 366.163 100,0%EIA MITIGATION AND RESETTLEMENT 2.134 0 2.134 0,6%OWNERS OWN COST 1,00% 1.301 2.309 3.610 1,0%TOTAL 138.678 233.229 371.907 101,6%

Table 9.12 : Summary of cost of the Madian Hydropower Project at level of prices 30. June 2008



9.10 Operation, Maintenance and Repair Costs

The Consultant assessed the operating costs for the project based on the technical data elaborated within the scope of previous tasks. These costs will be divided into:

• maintenance costs for all productive assets; • operation costs; • personnel costs, including expenses for technical staff required to

supervise and to operate the system; • training costs; • Administration costs associated with the project, including such cost

items as office costs, insurance, equipment and materials. Recurrent annual fixed costs for operation, maintenance and repairs (OMR) during the period of operation were calculated as a percentage of the initial investment costs. The following percentages were applied:

− Civil structures : 0.5%,

− Electro-mechanical equipment, : 2.0% including hydraulic steel structures

According to common experience in the operation of hydropower plants and in view of the assumed concession period of 30 years, an overhaul of equipment (electro-mechanical, electrical and hydraulic steel structure) will be assumed as follows:

a) Electrical control and protection equipment after 15-20 years of operation (16.6 % of electrical equipment cost);

b) Electro-mechanical equipment components after 20-25 years

of operation; (15 % of electro-mechanical equipment cost);

c) Hydraulic Steel structure equipment components (and valves) after 30 years (end of concession period) of operation.

These overhaul does not form part of the annual OMR cost.

ANNEX 9 Billl of Quantities & Cost Estimates

7166P02/BoQ and Cost Estimates A-9-1

Annex A-9.1: Quotation of Material Unit Prices of Manufacturers /Suppliers









Annex A-9.2a: Cost of Construction Equipment - Monthly Rental

Rental Price / Month No. Description of Equipment

Pak Rps. US $

1 Excavator face shovel 0.5 – 1.1 m³ 250000 3906

2 Front end loader 0.75 m³ 124500 1945

3 Dozer D-7 (Compatible) 280950 4390

4 Dozer D-8 (Compatible) 386000 6031

5 Dozer 3.5 m³ 195100 3048

6 Rock drilling equipment other than drill jumbo 515550 8055

7 Mucking truck with rock body 14 tonne 85750 1340

8 Dump truck 7.5~20 m³ 114400 1788

9 Vibratory roller 15 tonne 250600 3916

10 Grader cat D-12 192400 3006

11 Tamping foot roller 15 ton 275000 4297

12 Scraper 15 m³ capacity 251000 3922

13 Air compressor diesel – 800 cfm 91750 1434

14 Air compressor electric 250 lb 145600 2275

15 Concrete breaker (Pneumatic hammer) 165500 2586

16 Concrete batch plant 22 m³ 540800 8450

17 Concrete transit mixer 190000 2969

18 Concrete pump static (40 m³/hr) 300000 4688

19 Concrete mobile pump (40 m³/hr) 291200 4550

20 Grouting equipment 93600 1463

21 Dewatering pump (1 cusec) 165500 2586

22 Concrete vibrator 55000 859

23 Tractor trolley 105000 1641

24 Water sprinkler 1000~3000 gal 92560 1446

25 Diesel generator 250 kVA 130000 2031


Annex A-9.2b: Cost of Construction Equipment – Operating Cost

Sr. # Equipment Rps/hr

1 Excavator 1.1 m³ 950

2 Dumper 35 m³ 550

3 Dozer 23.5 Ton 1740

4 Grader (190 HP) 925

5 Rock drilling machine 3300

6 Air compressor 800 cfm 580

7 Transit mixer 4 m3 900

8 Concrete pump static 45 m3/hr 1400

9 Vibrator 250

10 Flat bed truck 550


Annex A-9.3: Comparative Statement of Unit Rates of 6 Hydropower Projects


MADIAN HYDRO POWER PROJECT MADIAN HYDRO POWER LTD FICHTNER GMBHINTAKE FOR LEFT BANK DIVERSION TUNNEL

Calculated physical parameters

Design discharge 129 m³/s Freeboard 1,5 mElevation of dam crest 1496 m asl Inner conduit diameter 9 mMaximum flood level 1495 m asl Width of entrance 18,9 m

COST ESTIMATE FOR DIVERSION TUNNEL INTAKEUNIT RATE TOTAL COST

No. CODE DESCRIPTION UNIT QUANTITY Local Foreign Unit Price Local Foreign TotalUS$ US$ US$ US$ US$ US$

1 IN0001 Underground rock excavat. class 4 m3 1.571,0 43,11 52,69 95,80 67.723 82.773 150.4962 IN0002 Shortcrete lining > 20 m2 m3 176,3 77,40 94,60 172,00 13.645 16.677 30.3233 IN0003 Concrete lining > 20 m2 m3 228,0 65,68 80,27 145,95 14.974 18.302 33.2774 IN0004 Steel reinforcement ton 17,1 786,50 643,50 1430,00 13.449 11.004 24.4535 IN0005 Mesh reinforcement ton 2,0 1056,83 864,68 1921,50 2.114 1.729 3.8436 IN0006 Formw.intake struc.tunn. 120m2 m² 3.757,0 7,73 9,44 17,17 29.024 35.474 64.4987 IN0007 Rockbolt m 470,0 17,50 14,32 31,82 8.224 6.729 14.9538 IN0008 Excavation open cut m³ 11.650,0 4,18 3,42 7,6025 48.713 39.856 88.5699 IN0009 Concrete in superstructure m³ 1.310,0 58,12 71,03 129,15 76.134 93.053 169.187

10 IN0010 Reinforcement superstructure ton 157,2 786,50 643,50 1430,00 123.638 101.158 224.796

Subtotal 397.639 406.755 804.394Miscellaneous items 15 % 59.646 61.013 120.659Total 457.285 467.769 925.053

COST ESTIMATE FOR D/S COFFERDAM UNIT RATE TOTAL COST


1 CO0001 Excavation cofferdam base m3 1.303,0 6,03 4,94 10,97 7.862 6.432 14.2942 CO0002 Preparation rock foundation m3 0,0 7,09 8,66 15,75 0 0 03 CO0003 Crushed rockfill S quantity m3 2.217,0 7,21 5,90 13,10 15.978 13.073 29.0524 CO0004 Extra for transport m3 km 3.309,0 0,76 0,41 1,18 2.529 1.362 3.8915 CO0005 Gabions m3 780,0 21,46 7,15 28,61 16.738 5.579 22.3186 CO0006 Borepile wall D = 0.8 m m 875,0 142,87 116,90 259,77 125.015 102.285 227.3017 CO0007 Concrete for bore piling m³ 439,82 63,24 51,74 114,98 27.813 22.756 50.5698 CO0008 Reinforcement for bore piling to 15,4 785,98 643,07 1429,05 12.099 9.899 21.999


COST ESTIMATE FOR COFFERDAM GROUTING UNIT RATE TOTAL COST


1 CO0022 percussion drilling open m 4.247,0 53,13 43,47 96,60 225.643 184.617 410.2602 CO0025 grouting open incl. cement to 774,0 287,02 234,83 521,85 222.152 181.760 403.9123 CO0029 rotary drilling (check hole) m 162 61,22 50,09 111,30 9.917 8.114 18.0314 CO0030 rotary drilling (drain hole) m 999 61,22 50,09 111,30 61.154 50.035 111.189

Subtotal 518.865 424.526 943.391Miscellaneous items 15 % 77.830 63.679 141.509Total 596.695 488.205 1.084.900

MADIAN HYDRO POWER PROJECT MADIAN HYDRO POWER LTD FICHTNER GMBHUPSTREAM ROCKFILL COFFERDAM


Elevation COFFERDAM crest 1496 m asl Maximum height of cofferdam 20,5 mWidth of dam crest 6 m Length of dam crest 60 mEmbankment slope UPSTREAM 2,0 Total cofferdam volume 35514 m3Embankment slope downstream 2,0Hauling distance rock 0,5 kmHauling distance impervious material 0,5 km

COST ESTIMATE FOR U/S COFFERDAM UNIT RATE TOTAL COST


1 CO0001 Excavation cofferdam base m3 3.577,0 6,03 4,94 10,97 21.582 17.658 39.2402 CO0002 Preparation rock foundation m3 0,0 8,66 7,09 15,75 0 0 03 CO0003 Extra for transport m3 km 29.900,0 0,75 0,42 1,18 22.504 12.658 35.1624 CO0004 Crushed rockfill S quantity m3 25.850,0 7,21 5,90 13,10 186.306 152.432 338.7385 CO0005 Dumped rock slope protection m3 4.050,0 10,67 8,73 19,40 43.222 35.364 78.5866 CO0006 Concrete slab at crest m3 117,0 65,45 53,55 119,00 7.658 6.265 13.923


Annex 9.4: Bill of Quantities of Madian Hydropower Project

1. Diversion Works


MADIAN HYDRO POWER PROJECT MADIAN HYDRO POWER LTD FICHTNER GMBHLEFT BANK DIVERSION TUNNEL


Design discharge 656 m³/s Number of tunnels 1Inner tunnel Dimnsions Height 9,2 m Tunnel length 265 mInner tunnel Dimnsions Width 8 m Flow velocity 10 m/sDesign head 9 m Lining thickness 0,6 mEquivalent roughness (k-value) 0,6 mm Shotcrete 0,1 m

Equivalent internal Dia 9,25Excavated Diameter 10,95

COST ESTIMATE FOR DIVERSION TUNNELUNIT RATE TOTAL COST


1 TU0013 Tunnel exc. cl.1-2-3, 60m2, 500m m3 24.955,4 31,77 59,00 90,76 792.750 1.472.249 2.264.9992 TU0033 Tunnel excavat. cl.4, 60m2, 500m m3 0,0 33,53 62,27 95,80 0 0 03 TU0053 Tunnel excavat. cl.5, 60m2, 500m m3 0,0 34,03 63,20 97,23 0 0 04 TU0062 Shotcrete > 20 m2 m³ 903,3 51,60 120,40 172,00 46.608 108.753 155.3615 TU0064 Concrete lining > 20m2 m³ 6.243,9 74,43 71,52 145,95 464.763 446.537 911.2996 TU0065 Reinforcement ton 405,9 786,50 643,50 1430,00 319.205 261.167 580.3727 TU0066 Mesh reinforcement m3 22,8 1056,83 864,68 1921,50 24.096 19.715 43.8108 TU0070 Formwork tunnels 500m, 60m2 m2 5.580,8 11,59 7,73 19,32 64.693 43.129 107.8229 TU0087 Rockbolt m 6.976,0 18,45 13,36 31,82 128.727 93.216 221.943

10 TU0091 Concrete for plug m² 1.570,0 94,87 51,08 145,95 148.942 80.200 229.142Subtotal 1.989.782 2.524.965 4.514.747Miscellaneous items 10 % 198.978 252.496 451.475Total 2.188.761 2.777.461 4.966.222

COST ESTIMATE FOR DIVERSION TUNNEL OUTLETUNIT RATE TOTAL COST


1 IN0001 Rock excavat. class 4 m3 1.571,0 43,11 52,69 95,80 67.723 82.773 150.4962 IN0002 Shortcrete lining > 20 m2 m3 176,3 77,40 94,60 172,00 13.641 16.673 30.3143 IN0003 Concrete lining > 20 m2 m3 228,0 65,68 80,27 145,95 14.974 18.302 33.2774 IN0004 Steel reinforcement ton 17,1 786,50 643,50 1430,00 13.449 11.004 24.4535 IN0005 Mesh reinforcement ton 2,0 1056,83 864,68 1921,50 2.114 1.729 3.8436 IN0006 Formw.intake struc.tunn. 120m2 m² 2.854,2 7,73 9,44 17,17 22.050 26.950 48.9997 IN0007 Rockbolt m 410,0 17,50 14,32 31,82 7.174 5.870 13.0448 IN0008 Excavation open cut m³ 4.420,0 4,18 3,42 7,6025 18.482 15.121 33.6039 IN0009 Concrete in superstructure m³ 1.210,0 58,12 71,03 129,15 70.322 85.949 156.272

10 IN0010 Reinforcement superstructure ton 145,2 786,50 643,50 1430,00 114.200 93.436 207.636



MADIAN HYDRO POWER PROJECT MADIAN HYDRO POWER LTD FICHTNER GMBHPOWER INTAKE


Design discharge 129 m³/s Freeboard 1 mElevation of dam crest 1496 m asl Inner conduit diameter 7 mMaximum flood level 1494,5 m asl

COST ESTIMATE FOR POWER TUNNEL INTAKEUNIT RATE TOTAL COST


1 IN0001 Common excavat. m3 18.000,0 3,80 3,80 7,60 68.423 68.423 136.8452 IN0002 Rock excavation m3 1.343,0 7,88 7,88 15,75 10.576 10.576 21.1523 IN0003 Shotcrete m3 84,0 51,60 120,40 172,00 4.334 10.113 14.4484 IN0004 Backfill m3 926,0 4,33 1,44 5,78 4.011 1.337 5.3485 IN0005 Formw.intake struc.tunn. 120m2 m² 2.116,0 6,87 10,30 17,17 14.531 21.796 36.3266 IN0006 Rockbolt m 754,0 18,45 13,36 31,82 13.913 10.075 23.9897 IN0007 Concrete in superstructure m³ 4.160,8 65,87 63,28 129,15 274.057 263.310 537.3678 IN0008 Reinforcement superstructure ton 499,3 786,50 643,50 1430,00 392.696 321.297 713.9939 IN0009 -tunnel excav. cl.4, 60m2, 500m m³ 1.963,0 33,53 62,27 95,80 65.817 122.231 188.048

Subtotal 848.358 829.158 1.677.516Miscellaneous items 10 % 84.836 82.916 167.752Total 933.194 912.074 1.845.268

COST ESTIMATE FOR BORE PILING - WEIR UNIT RATE TOTAL COST


1 DA0046 pile drilling m 5.540,0 38,97 220,81 259,77 215.871 1.223.268 1.439.1392 CO0025 concrete for piles m³ 2.784,7 63,24 51,74 114,98 176.094 144.077 320.1723 CO0029 reinforcement for piles to 62,7 785,98 643,07 1429,05 49.296 40.333 89.628

Subtotal 441.261 1.407.678 1.848.939Miscellaneous items 10 % 44.126 140.768 184.894Total 485.387 1.548.446 2.033.833Specific cost per m2 grout area US$/m² 229

COST ESTIMATE FOR WEIR GROUTING UNIT RATE TOTAL COST


1 DA0046 Percussion drilling open m 3.191,0 43,47 53,13 96,60 138.713 169.538 308.2512 CO0025 Grouting open incl. cement to 1.534,0 234,83 287,02 521,85 360.233 440.285 800.5183 CO0029 rotary drilling (check hole) m 165 50,09 61,22 111,30 8.264 10.100 18.3654 CO0030 rotary drilling (drain hole) m 1015 50,09 61,22 111,30 50.836 62.133 112.970


MADIAN HYDRO POWER PROJECT MADIAN HYDRO POWER LTD FICHTNER GMBHCONVENTIONAL CONCRETE GRAVITY WEIR


Elevation dam crest 1496 m asl Maximum height of cofferdam 31 mWidth of dam crest 4,5 m Length of dam crest 88 mEmbankment slope UPSTREAM 0,0 Total dam volume 17795 m3Embankment slope downstream 0,8 Average depth of excavation 11,1 mHauling distance concrete aggregates 3 km

COST ESTIMATE FOR WEIRUNIT RATE TOTAL COST


1 WE0001 Site clearing light jungle ha 1,5 339,89 183,02 522,90 510 275 7842 WE0002 Common excavation m3 117.582,0 3,42 4,18 7,60 402.263 491.654 893.9173 WE0003 Rock excavation m3 35.274,6 7,09 8,66 15,75 250.009 305.566 555.5754 WE0004 Preparation of foundation m² 2.273,0 7,09 8,66 15,75 16.110 19.690 35.8005 WE0005 Backfill m3 10.713,0 2,60 3,18 5,78 27.840 34.027 61.8687 WE0007 Concrete to structures m3 39.811,0 71,03 58,12 129,15 2.827.875 2.313.716 5.141.5918 WE0008 Extra transport crushed stone m3 km 109.428,0 0,76 0,41 1,18 83.647 45.041 128.6879 WE0009 Bar reinforcement complete to 534,5 786,50 643,50 1430,00 420.375 343.943 764.318

10 WE0010 Formwork S m² 9.545,0 9,44 7,73 17,17 90.125 73.739 163.864Subtotal 4.118.753 3.627.650 7.746.403Miscellaneous items 10 % 411.875 362.765 774.640Total 4.530.628 3.990.415 8.521.044

2. Weir Structure


MADIAN HYDRO POWER PROJECT MADIAN HYDRO POWER LTD FICHTNER GMBHSURGE TANK


number of Surge Tanks 1Inner diameter 21 m Inner diameter 21,00 Overbreak, Lining Shotcrete ExcavatedExcavated diameter 23,2 m Tunnel m Thickness Thickness DiameterHeight of surge tank 83 min overburden 3 % in fair rock 0,30 0,60 0,20 23,20Spacing of Rock Bolts 3 m²Discharge in Tunnel 129 m3/sProvisions for maintenace gate 9,9 m²

COST ESTIMATE FOR PRESSURE TUNNELUNIT RATE TOTAL COST


1 ST0003 Shaft excavation m3 35087 31,77 59,00 90,76 1.114.592 2.069.957 3.184.5492 ST0010 Shotcrete (15-20 cm thickness) m2 1199 60,20 111,80 172,00 72.205 134.096 206.3013 ST0011 Concrete in Surge Tank m3 5785 74,43 71,52 145,95 430.588 413.702 844.2904 ST0012 Reinforcing steel to 260 786,50 643,50 1430,00 204.738 167.513 372.2515 ST0013 Mesh reinforcement to 17 1056,83 864,68 1921,50 18.283 14.959 33.2426 ST0014 Formwork m2 5613 10,63 8,69 19,32 59.644 48.799 108.4436 ST0019 Rockbolt m 13097 18,45 13,36 31,82 241.675 175.006 416.6817 ST0024 Excavation open cut m3 3368 4,94 2,66 7,60 16.642 8.961 25.604

Subtotal 2.158.368 3.032.993 5.191.361Miscellaneous items 15 % 323.755 454.949 778.704Total 2.482.123 3.487.942 5.970.065

COST ESTIMATE FOR DESANDER CAVERNUNIT RATE TOTAL COST


1 PH0007 Excavationcavern cl.1-2-3 m3 201024 22,56 41,89 64,45 4.534.529 8.421.267 12.955.7962 PH0008 Rock bolt m 69300 18,45 13,36 31,82 1.278.772 926.007 2.204.7803 PH0015 Wire mesh ton 123 1056,83 864,68 1921,50 129.910 106.290 236.2004 PH0016 Shotcrete lining m3 7450 51,60 120,40 172,00 384.409 896.954 1.281.3635 PH0017 Concrete to cavern m3 21000 65,68 80,27 145,95 1.379.228 1.685.723 3.064.9506 PH0018 Reinforcement to cavern ton 1260 786,50 643,50 1430,00 990.990 810.810 1.801.8007 PH0019 Formwork to covern lining m2 7115 8,31 10,15 18,46 59.099 72.233 131.332

Subtotal 8.756.937 12.919.284 21.676.221Miscellaneous items 10 % 875.694 1.291.928 2.167.622Total 9.632.630 14.211.212 23.843.843

MADIAN HYDRO POWER PROJECT MADIAN HYDRO POWER LTD FICHTNER GMBHHEADRACE TUNNEL


number of tunnels 1 Inner dia 7,00 Overbreak, Lining Shotcrete Excavatedtunnel Length 11821 m Length m Thickness Thickness Diameterin good rock 35,7% % in very good 0 0,10 0,00 0,05 7,20in fair rock 57,9% % in good rock 4215 0,10 0,30 0,08 7,80in poor rock 6,1% % in fair rock 6840 0,15 0,50 0,10 8,30in very poor rock 0,4% % in poor rock 716 0,20 0,60 0,15 8,60Flow velocity 3,35 m/s in very poor 50 0,20 0,60 0,20 8,60Discharge in Tunnel 129 m3/s 11821

COST ESTIMATE FOR HEADRACE TUNNELUNIT RATE TOTAL COST


1 PT0017 Tunnel exc. cl.1-2-3 m3 571494 31,77 59,00 90,76 18.154.464 33.715.434 51.869.8982 PT0018 Tunnel exc. cl.4 m3 41591 33,53 62,27 95,80 1.394.493 2.589.772 3.984.2653 PT0019 Tunnel exc. cl.5 m3 2904 29,17 68,06 97,23 84.718 197.675 282.3944 PT0062 Shotcrete (7.5-20 cm thickness) m3 28408 51,60 120,40 172,00 1.465.786 3.420.166 4.885.9525 PT0064 Concrete lining m3 132656 74,43 71,52 145,95 9.874.190 9.486.966 19.361.1566 PT0065 Reinforcement to 3980 786,50 643,50 1430,00 3.130.020 2.560.926 5.690.9467 PT0066 Mesh Reinforcement to 232 1056,83 864,68 1921,50 245.183 200.605 445.7888 PT0071 Formwork tunnels m2 258390 7,73 11,59 19,32 1.996.838 2.995.257 4.992.0959 PT0087 Rockbolt 3-4 m long, 25mm m 199941 18,45 13,36 31,82 3.689.457 2.671.676 6.361.133

10 PT0088 Steel rib to 1214 825,83 675,68 1501,50 1.002.552 820.269 1.822.82111 PT0089 Steel lagging to 390 825,83 675,68 1501,50 322.072 263.513 585.585

Subtotal 41.359.773 58.922.260 100.282.033Miscellaneous items 10 % 4.135.977 5.892.226 10.028.203Total 45.495.750 64.814.487 110.310.237

3. Power Waterways – Headrace Tunnel & Desander Cavern


MADIAN HYDRO POWER PROJECT MADIAN HYDRO POWER LTD FICHTNER GMBHMANIFOLD


Number of units 3Flow velocity 6,08 m/s Inner diameterLength Overbreak, Lining Shotcrete ExcavatedSpacing of Rock Bolts 3 m Tunnel m Thickness Thickness DiameterDischarge in Tunnel 129 m3/s 5,40 19,3 0,20 0,50 0,10 7,00Steel Linning Thickness 0,028 m 4,25 18,4 0,20 0,50 0,10 5,85

3,00 131 0,20 0,40 0,10 4,40



1 PT0017 Tunnel exc. cl.1-2-3 m3 3552 31,77 59,00 90,76 112.839 209.559 322.3982 PT0062 Shotcrete (15cm thickness) m3 252 51,60 120,40 172,00 13.005 30.345 43.3503 PT0064 Concrete lining m3 1483 74,43 71,52 145,95 110.383 106.054 216.4374 PT0065 Reinforcement to 786,50 643,50 1430,00 0 0 05 PT0066 Mesh Reinforcement to 2 1066,43 855,07 1921,50 2.133 1.710 3.8436 PT0071 Formwork tunnels m2 0 9,66 9,66 19,32 0 0 07 PT0087 Rockbolt 3m long, 25mm m 2573 18,45 13,36 31,82 47.486 34.387 81.873


MADIAN HYDRO POWER PROJECT MADIAN HYDRO POWER LTD FICHTNER GMBHPRESSURE TUNNEL


number of tunnels 1tunnel Length 67 m Inner diameter 5,40 Overbreak, Lining Shotcrete Excavatedin good rock 50 % Tunnel m Thickness Thickness Diameterin fair rock 20 % in good rock 0,05 0,30 0,10 6,30in poor rock 15 % in fair rock 0,08 0,50 0,15 6,85in very poor rock 15 %Flow velocity 5,63 m/sSpacing of Rock Bolts 3 mDischarge in Tunnel 129 m3/s Steel Linning Thickness 0,028 m



1 PT0017 Tunnel exc. cl.1-2-3 m3 2257 31,77 59,00 90,76 71.708 133.172 204.8802 PT0062 Shotcrete (15cm thickness) m3 130 51,60 120,40 172,00 6.693 15.618 22.3123 PT0064 Concrete lining m3 421 74,43 71,52 145,95 31.343 30.113 61.4564 PT0065 Reinforcement to 0 786,50 643,50 1430,00 0 0 05 PT0066 Mesh Reinforcement to 1 1056,83 864,68 1921,50 1.057 865 1.9226 PT0071 Formwork tunnels m2 0 7,73 11,59 19,32 0 0 07 PT0087 Rockbolt 3m long, 25mm no 1318 18,45 13,36 31,82 24.323 17.614 41.937


MADIAN HYDRO POWER PROJECT MADIAN HYDRO POWER LTD FICHTNER GMBHPRESSURE SHAFT


number of tunnels 1tunnel Length 112 m Inner diamete 5,80 Overbreak, Lining Shotcrete Excavatedin good rock 60 % Tunnel m Thickness Thickness Diameterin fair rock 30 % in good rock 0,05 0,30 0,10 6,70in poor rock 10 % in fair rock 0,08 0,50 0,15 7,25Flow velocity 4,88 m/sSpacing of Rock Bolts 3 m²Discharge in Tunnel 129 m3/s



1 PS0005 Shaft excavation m3 4254 31,77 59,00 90,76 135.129 250.954 386.0842 PS0019 Shortcrete lining (15cm thickness) m2 373 51,60 120,40 172,00 19.249 44.915 64.1643 PS0020 Concrete lining m3 754 74,43 71,52 145,95 56.123 53.922 110.0454 PS0022 Reinforcement to 34 786,50 643,50 1430,00 26.686 21.834 48.5205 PS0023 Mesh Reinforcement to 1 1056,83 864,68 1921,50 1.057 865 1.9226 PT0071 Formwork tunnels m2 1530 7,73 11,59 19,32 11.824 17.736 29.5607 PS0024 Rockbolt 3m long, 25mm m 2443 18,45 13,36 31,82 45.085 32.648 77.732



COST ESTIMATE FOR TAILRACE TUNNEL OUTLETUNIT RATE TOTAL COST


1 OL0001 common excavation in open cut m3 48.120,0 4,18 3,42 7,60 201.208 164.625 365.8322 OL0002 rock excavation in open cut m3 5.230,0 8,66 7,09 15,75 45.305 37.068 82.3732 OL0002 Shortcrete lining > 20 m2 m3 123,0 51,60 120,40 172,00 6.347 14.809 21.1553 OL0003 Concrete lining > 20 m2 m3 511,0 74,43 71,52 145,95 38.036 36.544 74.5804 OL0004 Steel reinforcement ton 46,0 786,50 643,50 1430,00 36.179 29.601 65.7805 OL0005 Mesh reinforcement ton 1,0 1056,83 864,68 1921,50 1.057 865 1.9226 OL0006 Formw.intake struc.tunn. 120m2 m² 710,0 9,44 7,73 17,17 6.704 5.485 12.1897 OL0007 Rockbolt m3 1.220,0 18,45 13,36 31,82 22.512 16.302 38.8149 OL0009 Concrete in superstructure m³ 750,0 65,87 63,28 129,15 49.400 47.463 96.863

10 OL0010 Reinforcement superstructure ton 75,0 786,50 643,50 1430,00 58.988 48.263 107.25011 OL0011 Formwork in superstructure m² 810,0 9,44 7,73 17,17 7.648 6.258 13.90612 OL0012 -tunnel excav. cl.4, 60m2, 500m m³ 871,0 31,77 59,00 90,76 27.669 51.385 79.054

Subtotal 501.052 458.666 959.717Miscellaneous items 15 % 75.158 68.800 143.958Total 576.209 527.465 1.103.675

MADIAN HYDRO POWER PROJECT MADIAN HYDRO POWER LTD FICHTNER GMBHTAILRACE TUNNEL

TAILRACE TUNNEL STRUCTURE Calculated physical parameters

Inner diameterOverbreak, number of tunnels 1 7,2 m lining Thickness, Excav diametertunnel Length 95 min very good rock 0 % 0,0 0,100 0 7,4 min good rock 20 % 19,0 0,075 0,3 m 7,95 min fair rock 50 % 47,5 0,100 0,5 m 8,4 min poor rock 30 % 28,5 0,100 0,6 m 8,6 mFlow velocity 3,17 m/sSpacing of Rock Bolts 3 m²

COST ESTIMATE FOR TAILRACE TUNNELUNIT RATE TOTAL COST


1 PT0017 Tunnel exc. cl.1-2-3 m3 3575 31,77 59,00 90,76 113.581 210.937 324.5182 PT0018 Tunnel exc. cl.4 m4 1656 33,53 62,27 95,80 55.507 103.085 158.5923 PT0019 Tunnel exc. cl.5 m5 0 34,03 63,20 97,23 0 0 03 PT0062 Shotcrete m2 251 51,60 120,40 172,00 12.936 30.183 43.1193 PT0064 Concrete lining m3 1397 74,43 71,52 145,95 103.967 99.889 203.856

65 PT0065 Reinforcement to 56 786,50 643,50 1430,00 43.942 35.952 79.89466 PT0066 Mesh Reinforcement to 2 1056,83 864,68 1921,50 2.114 1.729 3.84371 PT0071 Formwork tunnels m2 1937 7,73 11,59 19,32 14.969 22.454 37.42387 PT0087 rockbolt 4m long, 25mm no 2507 18,45 13,36 31,82 46.261 33.499 79.76088 PT0088 steel rib to 12 825,83 675,68 1501,50 10.240 8.378 18.619

Subtotal 403516 546107 949623Miscellaneous items 10 % 40.352 54.611 94.962Total 443.868 600.718 1.044.585

MADIAN HYDRO POWER PROJECT MADIAN HYDRO POWER LTD FICHTNER GMBHDRAFTTUBE EXTENSION


number of units 3Flow velocity 3,17 m/s Inner diamete Length Overbreak, Lining Shotcrete ExcavatedSpacing of Rock Bolts 3 m Tunnel m Thickness Thickness DiameterDischarge in Tunnel 129 m3/s 7,20 19,3 0,20 0,50 0,15 8,90

5,60 18,4 0,20 0,50 0,15 7,304,20 131 0,20 0,40 0,10 5,60



1 PT0017 Tunnel exc. cl.1-2-3 m3 5197 31,77 59,00 90,76 165.102 306.618 471.7203 PT0062 Shotcrete m2 368 51,60 120,40 172,00 18.985 44.297 63.2823 PT0064 Concrete lining m3 1775 74,43 71,52 145,95 132.157 126.974 259.131

65 PT0065 Reinforcement to 89 786,50 643,50 1430,00 69.821 57.126 126.94766 PT0066 Mesh Reinforcement to 10 1056,83 864,68 1921,50 10.320 8.444 18.76471 PT0071 Formwork tunnels m2 2489 9,66 9,66 19,32 24.042 24.042 48.08387 PT0087 rockbolt 4m long, 25mm no 3733 18,45 13,36 31,82 68.887 49.884 118.770



COST ESTIMATE FOR CABLE TUNNELUNIT RATE TOTAL COST


1 TU0009 Tun.exc. cl.1-2-3, 30m2, 500m 21 m3 1882 31,77 59,00 90,76 59798,11 111053,63 170.8522 TU0029 Tun.excavat. cl.4, 30m2, 500m m3 807 33,53 62,27 95,80 27049,24 50234,29 77.2843 TU0061 Shotcrete < 20 m2 m3 183 51,60 120,40 172,00 9447,27 22043,64 31.4913 TU0063 Concrete lining < 20m2 m3 517 74,43 71,52 145,95 38511,00 37000,76 75.512

65 TU0065 Reinforcement to 23 786,50 643,50 1430,00 18311,41 14982,06 33.29366 TU0066 Mesh reinforcement to 1 1056,83 864,68 1921,50 1395,01 1141,37 2.53671 TU0069 Formwork tunnels 500m, 30m2 m2 561 9,66 9,66 19,32 5419,26 5419,26 10.83987 TU0087 Rockbolt m 1373 18,45 13,36 31,82 25339,07 18348,98 43.688


COST ESTIMATE FOR ACCESS TUNNEL POWERHOUSEUNIT RATE TOTAL COST


1 TU0009 Tun.exc. cl.1-2-3, 30m2, 500m m3 7201 31,77 59,00 90,76 228.747 424.816 653.5622 TU0029 Tun.excavat. cl.4, 30m2, 500m m3 3086 33,53 62,27 95,80 103.472 192.162 295.6343 TU0061 Shotcrete < 20 m2 m3 653 51,60 120,40 172,00 33.701 78.635 112.3363 TU0063 Concrete lining < 20m2 m3 1804 74,43 71,52 145,95 134.273 129.007 263.280

65 TU0065 Reinforcement to 81 786,50 643,50 1430,00 63.845 52.237 116.08166 TU0066 Mesh reinforcement to 4 1056,83 864,68 1921,50 4.227 3.459 7.68671 TU0069 Formwork tunnels 500m, 30m2 m2 2431 9,66 9,66 19,32 23.485 23.485 46.97187 TU0087 Rockbolt m 3233 18,45 13,36 31,82 59.658 43.201 102.859

Subtotal 651.408 947.001 1.598.409Miscellaneous items 15 % 97.711 142.050 239.761Total 749.119 1.089.052 1.838.170

COST ESTIMATE FOR SWITCHYARD CAVERNUNIT RATE TOTAL COST


1 PH0007 Excavationcavern cl.1-2-3 m3 5080 26,42 38,02 64 134.234 193.167 327.4012 PH0008 Rock bolt m 2606 18,45 13,36 32 48.086 34.821 82.9073 PH0009 Wire mesh ton 7 1056,83 864,68 1922 7.398 6.053 13.4514 PH0010 Shotcrete lining m3 250 51,60 120,40 172 12.900 30.099 42.9995 PH0011 Concrete to cavern m3 309 65,68 80,27 146 20.294 24.804 45.0996 PH0012 Reinforcement to cavern ton 37 786,50 643,50 1430 29.163 23.861 53.0247 PH0013 Formwork to cavern lining m2 1405 10,15 8,31 18 14.260 11.667 25.927

Subtotal 266335 324472 590807Miscellaneous items 15 % 39.950 48.671 88.621Total 306.286 373.142 679.428

COST ESTIMATE FOR TRANSFORMER CAVERNUNIT RATE TOTAL COST


1 PH0007 Excavationcavern cl.1-2-3 m3 4630 26,42 38,02 64 122.344 176.055 298.3992 PH0008 Rock bolt m 2418 18,45 13,36 32 44.619 32.310 76.9293 PH0009 Wire mesh ton 7 1056,83 864,68 1922 7.398 6.053 13.4514 PH0010 Shotcrete lining m3 257 51,60 120,40 172 13.261 30.942 44.2035 PH0011 Concrete to cavern m3 331 65,68 80,27 146 21.739 26.570 48.3096 PH0012 Reinforcement to cavern ton 40 786,50 643,50 1430 31.240 25.560 56.8007 PH0013 Formwork to covern lining m2 1703 10,63 8,69 19 18.096 14.806 32.902

Subtotal 258696 312296 570992Miscellaneous items 15 % 38.804 46.844 85.649Total 297.500 359.140 656.641

COST ESTIMATE FOR POWERHOUSE CAVERNUNIT RATE TOTAL COST


1 PH0007 Excavationcavern cl.1-2-3 m3 38184 26,42 38,02 64,45 1.008.984 1.451.953 2.460.9372 PH0008 Rock bolt m 6188 18,45 13,36 31,82 114.185 82.686 196.8713 PH0009 Wire mesh ton 53 1056,83 864,68 1921,50 56.012 45.828 101.8404 PH0010 Shotcrete lining m3 1487 51,60 120,40 172,00 76.701 178.969 255.6715 PH0011 Concrete to cavern m3 8019 65,68 80,27 145,95 526.668 643.705 1.170.3736 PH0012 Reinforcement to cavern ton 802 786,50 643,50 1430,00 630.694 516.023 1.146.7177 PH0013 Formwork to cavern lining m2 18923 19,80 16,20 36,00 374.666 306.545 681.210

Subtotal 2.787.910 3.225.708 6.013.618Miscellaneous items 15 % 418.186 483.856 902.043Total 3.206.096 3.709.564 6.915.661

4. Powerhouse, Transformer and Switchyard Cavern


Part Description No. / Unit Price FOB Transport Erection InstalledLot FOB Insurance

USD USD USD USD USD1,1 Spillway

Radial Tainter gate 2 682.500 1.365.000 68.250 273.000 1.706.250Radial Tainter Gate with Flap Gate 1 756.000 756.000 37.800 151.200 945.000Stoplogs lot 409.500 409.500 20.475 40.950 470.925Gantry crane lot 414.750 414.750 20.738 62.213 497.700

1,2 Power Intake & WaterwaysStoplogs lot 346.500 346.500 17.325 34.650 398.475Trash rack 3 157.500 472.500 23.625 70.875 567.000Trash rack Cleaning Machine lot 262.500 262.500 13.125 39.375 315.000Intake Roller gate 3 155.925 467.775 23.389 93.555 584.719Flushing gate 2 110.250 220.500 11.025 44.100 275.625Stoplogs for Flushing Gate lot 154.350 154.350 7.718 30.870 192.938Steel Lining Flushing Channel lot 241.500 241.500 12.075 72.450 326.025

1,3 DesanderRoller gate Outlet 3 182.700 548.100 27.405 109.620 685.125Sliding gate Inlet 3 168.000 504.000 25.200 100.800 630.000Desander Mechanical Equipment 3 165.900 497.700 24.885 99.540 622.125Sluice Valve 6 15.750 94.500 4.725 18.900 118.125

1,4 WaterwaysBulkhead at Surge Tank 1 231.000 231.000 11.550 46.200 288.750Pressure Shaft Steel Liner lot 1.430.100 1.430.100 71.505 715.050 2.216.655

1,5 MiscellaneousTailrace Outlet Stoplog 1 205.800 205.800 10.290 41.160 257.250Draft tube flap gate 3 118.230 354.690 17.735 70.938 443.363Lost Stoplog Diversion Tunnel lot 336.000 336.000 16.800 50.400 403.200

Total Equipment Part US$ 11.944.249

Annex A-9.5: Cost Estimate of Hydraulic Steel Structure Equipment

Costs: Equipment installed, commissioned, spare parts included, without contingencies.


Item Description No. / Lot Unit Price FOB Transport & Erection InstalledInsurance

FOB USD USD USD USD

Turbines, Governors and Main Inlet ValvesP=60,8 MW, n=333,3 rpm, Hn=151,7m

1,1 Turbines incl. Governors 3 4.161.526 12.484.578 624.229 1.872.687 14.981.4931,2 Main Inlet Valves

Butterfly valve, D=2.5m 3 894.952 2.684.855 107.394 268.486 3.060.735Total Part 1 18.042.228

Power Plant Mechanical Equipment2,1 Cooling Water System 3 357.981 1.073.942 42.958 214.788 1.331.6882.2 Drainage and Dewatering System lot 447.476 447.476 17.899 89.495 554.870

2.3a Low Pressure Compressed Air System lot 170.041 170.041 6.802 34.008 210.8512.3b Low Pressure Compressed Air System lot 217.944 217.944 8.718 43.589 270.2512.4 Air Conditionning and Ventilation System lot 1.208.185 1.208.185 60.409 241.637 1.510.2312,5 Oil Treatment Plant lot 116.344 116.344 4.654 11.634 132.6322,6 Mechanical Workshop Equipment Lot 205.839 205.839 8.234 41.168 255.2402,7 EOT Crane Powerhouse 210 t 1 787.558 787.558 39.378 118.134 945.0692,8 Elevator 2 111.869 223.738 8.950 33.561 266.2482,9 Fire Fighting System lot 617.517 617.517 24.701 154.379 796.597

2,10Mandatory release generating unit, 520kW, H=16m, Q=3.6 m3/s, complett with generator and electrical/mechnical auxiliary systems

Lot 1.005.325 1.005.325 50.266 150.799 1.206.390

Total Part 2 7.480.067Grandotal Equipment Parts 1&2, 25.522.295Misellaneous items 2.5 % 638.057Grandtotal 26.160.353

Annex A-9.6: Cost Estimate of Electro-Mechanical Equipment

Costs: Equipment installed, commissioned, spare parts included, without contingencies.


MADIAN HYDROPOWER PROJECTCost Estimate for Electro-mechanical Equipment

Item Description Unit No. / Lot Unit Price Transp. + Insu Erection InstalledFOB FOB US$ US$ US$ US$ US$

Main Generators, Excitation Systems andAssociated Auxiliary Equipment

1.01 Generator 63 MVA, 333.3 rpm, 18 poles 3 5.707.284 17.121.851 1.027.311 2.054.622 20.203.7841.02 Static Excitation System in item 1.011.03 Fire Protection System for Generator in item 1.01

Total Part 1 17.121.851 1.027.311 2.054.622 20.203.784

Electrical Equipment within / at Power Cavern 0,0600 0,30002.01 220 kV Terminal Gantry to OHLs & Surge Arrestors Lot 93.180 93.180 5.591 27.954 126.7252.02 220 kV XLPE cable connection OHL terminal gantry - GIS switchgear km 0,3 931.801 279.540 16.772 83.862 380.1752.03 220 kV XLPE cable connection GIS switchgear - Main Transformers km 0,12 640.613 76.874 4.612 23.062 104.548

2.04 220 kV GIS Switchgear Bays 6 838.621 5.031.728 301.904 603.807 5.937.4382.05 Main Single-Phase Transformer 230/13.8kV, 24 1/3 MVA 10 582.376 5.823.759 349.426 698.851 6.872.0352.06 Fire Protection System for Transformers Lot 151.418 151.418 9.085 30.284 190.7862.07 13.8 kV generator busbars system 3 359.559 1.078.677 64.721 161.801 1.305.1992.08 13.8 kV generator circuit-breakers 2 326.130 652.261 39.136 78.271 769.6682.09 Unit Auxiliary Transformer 13.8/0.42 kV 1250 kVA 2 19.859 39.718 1.986 4.766 46.4702.10 400 V AC Switchgear incl. Sub-Boards Lot 407.663 407.663 20.383 101.916 529.9622.11 UPS Systems (110 V, 48 V, 24 V, Safe AC 400 V) Lot 135.111 135.111 6.756 33.778 175.6452.12 Emergency Diesel Generator Set 630 kVA 1 366.897 366.897 14.676 55.035 436.6072.13 Protection System

Unit Protection System 3 58.238 174.713 8.736 17.471 200.920GIS Switchgear & Transformer Protection System 6 58.238 349.426 17.471 34.943 401.839

2.14 Power, Control & Instrum. Cables + Cable Trays Lot 465.901 465.901 46.590 186.360 698.8512.15 Grounding and Lightning Protection System Lot 267.893 267.893 13.395 133.946 415.2342.16 Illumination and Small Power Lot 267.893 267.893 13.395 93.763 375.0502.17 Control and Monitoring System

Plant Control and Monitoring System Lot 582.376 582.376 17.471 58.238 658.085Unit and Common Control System 4 209.655 838.621 25.159 83.862 947.642GIS Switchgear Control System 6 46.590 279.540 8.386 27.954 315.881Dam Site & Desander Cavern Control Systems 2 209.655 419.311 12.579 41.931 473.821

2.18 Communication System Lot 151.418 151.418 4.543 45.425 201.3862.19 Electrical Workshop Equipment Lot 58.238 58.238 1.747 2.912 62.897

Total Part 2 17.992.153 1.004.518 2.630.192 21.626.863

Electrical Equipment at Dam Site3.01 11 kV Switchgear Lot 34.943 34.943 1.747 6.989 43.6783.02 Auxiliary Transformer 11/0.42 kV 630 kVA 1 17.937 17.937 717 2.691 21.3453.03 400 V AC Switchgear incl. Sub-Boards Lot 93.180 93.180 4.659 23.295 121.1343.04 UPS Systems (110 V, 48 V, 24 V, Safe AC 400 V) Lot 83.862 83.862 4.193 20.966 109.0213.05 Emergency Diesel Generator Set 150 kVA 1 94.345 94.345 3.774 14.152 112.2703.06 Auxiliary Synchronous Hydrogenerator 650 kVA, 400 V, 1500 rpm 1 227.127 227.127 9.085 34.069 270.2813.07 Protection Systems, Power, Control & Instrum. + Cable Trays, Lot 611.495 611.495 18.345 61.149 690.989

and Small Power Grounding and Lightning Protection System3.08 Control and Monitoring System in item 2.173.09 Communication System in item 2.18

Total Part 3 1.162.888 42.520 163.310 1.368.718

Electrical Equipment at Desander Cavern4.01 11 kV Switchgear Lot 34.943 34.943 1.747 6.989 43.6784.02 Auxiliary Transformer 11/0.42 kV 630 kVA 1 11.647 11.647 466 1.747 13.8604.03 400 V AC Switchgear incl. Sub-Boards Lot 81.533 81.533 4.077 20.383 105.9924.04 UPS Systems (110 V, 48 V, 24 V, Safe AC 400 V) Lot 83.862 83.862 4.193 20.966 109.0214.05 Emergency Diesel Generator Set 150 kVA 1 94.345 94.345 3.774 14.152 112.2704.06 Protection Systems, Power, Control & Instrum. + Cable Trays, Lot 314.483 314.483 9.434 31.448 355.366

Small Power, Grounding and Lightning Protection System,4.07 Control and Monitoring System in item 2.174.08 Communication System in item 2.18

Total Part 4 620.813 23.691 95.684 740.188

Total Electrical Equipment Part 1 to Part 4 36.897.704 2.098.041 4.943.809 43.939.553

Annex A-9.7: Cost Estimate of Electrical Equipment Costs: Equipment installed, commissioned, spare parts included, without contingencies.

Documents

Bill of Quantities and Cost Estimates - Gulam Faruquegfg.com.pk/mhpl/Madian Feasibility Study_200902/VOLUME II/Kap 09... · Bill of Quantities and Cost Estimates 9-1 ... Basic costs